TELEDYNE CONTINENTAL AIRCRAFT ENGINE SERVICE INFORMATION DIRECTIVE Compliance Will Enhance Safety, Maintenance or Economy of Operation CATEGORY 4 Technical Portions FAA Approved SUBJECT: PURPOSE: COMPLIANCE: MODELS AFFECTED: IO240B Fuel System Component Installation To provide instructions for the installation of a Factory Flushed fuel system component kit and instructions for reorientation of inline fuel filter. This is in support of Diamond Aircraft Service Bulletin DAC1-73-05 See Diamond Service Bulletin DAC1-73-05 for compliance IO240B13B, 17B, 20B, 21B engines equipped with Altitude Compensating Fuel Systems and IO240 engines modified per SIL05-4A to incorporate a 656859 inline fuel filter GENERAL Teledyne Continental Motors has introduced a Factory Flushed fuel system kit to reduce the potential for contaminants in engine fuel system components. The kit includes the following components; inline fuel filter, throttle body/metering unit, manifold valve, a set of position tuned fuel injection nozzles and all attaching hoses from the fuel pump to the manifold valve. The fuel component kit is furnished preassembled from the fuel pump to the manifold valve. All hoses are installed, capped and plugged to assure cleanliness in shipping and installation. The preassembled components are to be installed as a single unit. Fuel line fittings may be loosened to allow alignment during hose and component attachment, but are NOT to be disconnected. This section gives removal and installation instructions for the Manifold valve, Throttle body/metering unit, Fuel injection nozzles and associated hoses and hardware. CAUTION: All fuel system components must be handled with care with any openings sealed with appropriate clean caps and plugs prior to installation or immediately upon removal. The engine, tools and environment must be clean to minimize any potential for fuel system contamination. Fuel system purging instructions must be performed in the sequence provided in this SID. During Installation: (1) Select the proper size open-end wrenches that will fit the fitting body and hose or tubing end fitting. (2) Torque the hose or tubing end fitting to the specified torque using a properly certified calibrated torque wrench while maintaining sufficient force on the component fitting to prevent twisting and shear loads. MO DAY YEAR MO DAY YEAR T eledyne Continental M otors, Inc. 1 of 6 12 14 2007 2007 TELEDYNE CONTINENTAL MOTORS, INC P.O. Box 90 Mobile Alabama 251-438-3411
(3) Support the last fitting in the assembly on components that contain multiple fittings coupled in one location. (4) DO NOT over torque fittings. Procedure: WARNING Magnetos must be verified to be in the off position and grounded, and fuel must be selected to the off position when moving the propeller by hand, or personal injury may result. Referring to the airframe manufacturer s maintenance instructions: (a) Remove upper and lower engine cowlings from the aircraft (b) Remove electrical power from the aircraft. (c) Shutoff the fuel supply to the engine by closing the fuel shutoff valve. 1. Disconnect the four fuel injector lines from the manifold valve and cap the fuel injector line ends. Plug the openings in manifold valve. Disconnect the vapor return hose and the vent hose from the manifold valve, plug hose ends and cap manifold valve fittings. Remove and discard the three screws that secure the manifold valve to isolator plate. Remove manifold valve. 2. Disconnect the induction air hose from the throttle body. Install cap plugs or tape on both the throttle body inlet and the induction air hose openings. Disconnect the throttle control cable from the throttle body lever and retain hardware., Disconnect the throttle body assembly from the intake manifold leaving the fuel hoses connected. Retain the four 0.25 diameter nuts and flat washers. Discard the four lock washers and gasket. 3. Disconnect the inline fuel filter and bracket assembly from the forward apron by disengaging the camloc fasteners. Remove the fuel system fuel line cushion clamps and fuel system transducer at the vertical baffle. Cap the fuel transducer and discard the fuel transducer grommet. Plug the transducer tee. Disconnect the fuel pump to fuel filter hose from the fuel pump outlet fitting. Cap the fuel pump fitting and plug the fuel pump to filter hose. 4. Remove fuel filter assembly, throttle body assembly, manifold assembly, along with all attaching hoses as a single unit. This assembly is to be returned to TCM upon completion of installation. 5. Modify the existing opening in the forward baffle assembly as referenced in the figure below. All dimensions in mm s. See Diamond Service Bulletin DAC1-73-05 NOTE: A rotary tool with a sanding drum is recommended for the baffle modification. Insure that all fuel and air openings are sealed before starting. Carefully clean all surfaces after rework to avoid contamination. MO DAY YEAR MO DAY YEAR T eledyne Continental M otors, Inc. 2 of 6 12 14 2007 P.O. Box 90 Mobile Alabama 251-438-3411
NOTE: All caution must be exercised during maintenance of the fuel system NOT to allow any contaminants to enter the components, lines and fittings during installation. All surfaces surrounding the area where components are to be installed must be clean and free of all forms of contaminant before and during installation. Components must be flushed and verified to be free of contamination prior to final installation. 6. Remove new fuel system from packaging and lay on top of engine in the approximate installed position. Confirm hose and fitting clocking of the fuel pump to inline fuel filter hose. This hose must be installed prior to filter installation as it is not accessible when the filter is attached to the forward apron. When clocking is verified, torque fitting to 135-190 inch pounds using a calibrated torque wrench. See the figure below for clocking. P/N 646644S4Y5.00 Hose assembly Hose assemblies supplied with the 45º fittings in plane with the fuel filter assembly as shown P/N 656859A6 Fuel Filter Assembly. (Mounting Bracket Omitted for Clarity.) P/N 646644S4Y6.50 Hose assembly MO DAY YEAR MO DAY YEAR T eledyne Continental M otors, Inc. 3 of 6 12 14 2007 P.O. Box 90 Mobile Alabama 251-438-3411
7. Install the manifold valve to the isolator plate using the included hardware. Remove protective caps and plugs on manifold valve. Remove fuel injection line caps and attach the fuel injector lines (torque to 55-60 inch-lbs), fuel vapor return hose, and vent hose to the manifold valve body. 8. Install the supplied pressure transducer grommet. Place the pressure transducer Tee through the vertical baffle with new MS 35489-20 grommet installed per the drawing below. Remove plug from pressure transducer Tee and install the pressure transducer in accordance with the Diamond Maintenance Manual. Install the fuel system MS21919WCF10 cushion clamps per the drawing below. 9. Route the fuel pump to fuel filter line through the forward apron and attach the fuel filter to the apron by engaging the camloc fasteners on filter mounting bracket. It will be necessary to guide the fuel line around the back side of the engine driven fuel pump and into the correct position for installation. Assure that the four lockwired screws are on the lower side of the filter installation. Install the throttle body assembly using retained hardware, new supplied lock washers and new gasket. Torque attaching nuts to 90-110 inch-lbs. Assure that the metal cap part number 639494 is installed at the metered fuel pressure tee on the metering housing and torqued to 135-190 inch-lbs. 10. Restore electrical power to the aircraft. Select the fuel to ON. 11. Remove fuel pump outlet protective cap then flush a minimum of 1 quart of fuel through the pump into a coffee filter in a clean dry container using the aircraft boost pump. Check for contamination. If contamination is found, continue to flush until contaminant is no longer found. If no contamination is found, remove the protective plug from the fuel filter hose and connect to the fuel pump outlet fitting. Torque the fuel pump outlet fitting B nut and fuel pump to inline fuel filter hose B nut to 135 190 inch lbs with a calibrated torque wrench. MO DAY YEAR MO DAY YEAR T eledyne Continental M otors, Inc. 4 of 6 12 14 2007 P.O. Box 90 Mobile Alabama 251-438-3411
12. Remove fuel injector lines from fuel injector nozzles. Remove fuel injector nozzles from cylinder heads and set aside removed fuel nozzles. These nozzles should be returned with assembly above to TCM at completion of maintenance. 13. Verify that the fuel injector cylinder position number etched on the fuel injector nozzle wrench flat matches the correct cylinder position. The first digit in the 4 digit etched number is the cylinder position, example 1125 would indicate installation in cylinder number 1, 2120 in cylinder number 2 and so on. Apply a small amount of 646943 anti-seize lubricant to the fuel injector nozzle threads as illustrated in the figure below. Hand tighten the fuel injector nozzle into the cylinder head. Use a modified 6 point deep wall socket to torque the fuel injector to 55 65 in-lbs using a calibrated torque wrench. 14. Place a clean, dry cup at the cylinder end of each fuel injector line to capture fuel and inspect for contaminants. Flush the complete fuel system using the aircraft boost pump while observing the fuel coming out of the fuel injector lines. Two to three cups of fuel are recommended to allow full flush of the system and effective inspection for contaminants. If contamination is found, continue to flush until contaminants are removed. If no contamination is found, install each fuel injector line and torque nut to 40-45 in-lbs. 15. Visually inspect all hoses, attachment points and pressure test fuel system for leaks using airframe boost pump. Assure all hose fittings to be torqued and secure at this time. All steel hose B nuts in this system are torqued to 135-190 inch-lbs. If no leaks are found, proceed to fuel system setup. 16. Perform the fuel system setup and operation verification in accordance with the instructions and specifications contained in TCM bulletin SID07-3, revision A or later and the instructions contained in the latest revision of the IO-240 Maintenance Manual TCM Form X30621A. Assure that 639464 caps are installed on the fuel metering tee and the manifold tee pressure checking points. Make an engine logbook entry that has been complied with. WARNING Over priming can cause a flooded intake resulting in a hydraulic lock condition and subsequent engine damage or failure. If the engine is over primed, or flooded, make sure that all fuel has drained from the intake and cylinders prior to attempting engine start. MO DAY YEAR MO DAY YEAR T eledyne Continental M otors, Inc. 5 of 6 12 14 2007 P.O. Box 90 Mobile Alabama 251-438-3411
NOTE: Pressure altitude must be used when determining fuel system set-up values. To determine pressure altitude prior to take-off, set your altimeter to 29.92 in hg, and the altimeter will indicate your pressure altitude. 17. Using the airframe manufacturers instructions, return the aircraft to its normal configuration. WARRANTY Contact Teledyne Continental Motors Customer Service at 1-888-826-5465 for part kit availability and labor claim filing instructions to allow completion of the modification section of this Service Bulletin. Please provide the following information to TCM representative at time of contact; 1. Model and Serial number of the affected aircraft 2. Registration number 3. Engine Serial Number 4. Total time on engine 5. Owner s Name, Address and Telephone Contact info 6. FBO Name, Address and Telephone Contact info PARTS REQUIRED P/N EQ7495 IO240B Fuel System Modifications Kit 1 EA MO DAY YEAR MO DAY YEAR T eledyne Continental M otors, Inc. 6 of 6 12 14 2007 P.O. Box 90 Mobile Alabama 251-438-3411